Apparatus for carbonization and distillation of solid hydrocarbons



NOV. 27, 1934. G. KOMAREK 1,982,523

APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12, 1950 14 Sheets-$heet l Nov. 27, 1934. G, KOMAREK 1,932,523

APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet 2 G. KOMAREK Nov. '27, 1934.

APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet 5 gwuentoo gwuvntoz 1950 14 Sheets-Sheet 4 Nov. 27, 1934. G. KOMAREK APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12 G. KOMAREK Nov. 27, 1934.

' APPARATUS FOR CARBONIZATION AND DISTILLATION 0F SOLID HYDROCARBONS Original Filed May 12, 1950 14 Sheets-Sheet 5 NOV. 27, 1934. G KOMAREK 1,982,523

APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet 6 Nov. 27, 1934. G. KOMAREK 1,982,523

APPARATUS FOR CARBONIZATION AND DISTILLATION 0F SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet 7 G. KOMAREK 1,982,523

APPARATUS FOR CARBONIZATION AND DISTILLA'I'ION OF SOLID HYDROCARBONS Nov. 27, 1934.

Original Filed May 12, 1930 14 Sheets-Sheet 8 G. KOMAREK Nov. 27, 1934.

APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12, 193Q 14 Sheets-Sheet 9 gmentoz 6%wfiu Iamre G. KOMAREK 1,982,523

APPARATUS FOR CARBbNIZATION AND DISTILLATION OF' SOLID HYDROCARBONS Nov. 27, 1934.

14 Sheets-Sheet 10 Original Filed May 12, 1930 0004 m w h gwumtov m 1 w M Nov. 27, 1934. G. KOMAREK 1,982,523

APPARATUS FOR CARBONIZATION AND DISTILLATION 0F SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet 11 3min wJJAM/WW NOV. 27, 1934. KOMAREK 1,982,523

APPARA'Q US FOR CARBONIZATION AND DISTILLATION 0F SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet 12 Nov. 27, 1934.

G. KOMAREK APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCARBONS Original Filed May 12, 1930 14 Sheets-Sheet l5 GwQa Ema/e8.

G. KOMAREK 7 Original Filed May 12, 1930 14 Sheets-Sheet 14 APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDRQCARBONS Patented Nov. 27, 1934 APPARATUS FOR CARBONIZATION AND DISTILLATION OF SOLID HYDROCAR- BONS Gustav Komarek, Chicago, Ill., ass'lgnor to Berwind Fuel Company of Delaware, Chicago,

111., a corporation of Delaware Original application May 12, 1930, Serial No.

Divided and this application October 3, 1931, Serial No. 566,711

5 Claims. (01. 202-136) This invention relates to the carbonization and distillation of hydrocarbons preferably in solid form and more particularly pulverulent bituminous coal.

The object of the invention is to subject such material to a continuous treatment whereby a maximum amount of by-products will be obtained as well as an optimum quantity of coke.

The invention provides for the carbonization and distillation of hydrocarbons by an apparatus which will not only be rapid in operation, but will also be free from any complicated control features, to the end that a continuous process is evolvedwhich is extremely eiileient for large scale production.

It has heretofore been necessary to use inclined retorts or kilns of considerable length and retorts wherein the application of heat has taken place in accordance with a rather delicate system of zoning with relation to exothermic reactions have also been used.

The economic apparatus is one which will permit the efiicient treatment of the largest possible quantity of coal in the shortest period of time and with the smallest expenditure of fuel for heating.

With this in mind, the present invention contemplates the use of a retort in which the diameter or width is considerably greater with relation to the longitudinal dimensions of the retort than has heretofore ever been attempted. With a retort having a large transverse dimension, and a relatively short longitudinal dimension, the feeding and discharge tubes are disposed axially and are made of considerably less diameter than the diameter of the retort. In this manner the fuel will be fed into the retort and a definite fixed level will prevail comparable to the diameter or width of the retort and the consequent position of the centrally disposed inlet and outlet passages.

Therefore, the quantity of coal in the retort will always be maintained a. constant and the discharge will be controlled by'the extent of the feed and the speed of movement of the retort.

Combined with such a structure is a heating means and since there will always be present a normal amount of coal equal to substantially one half of the cubical content of the retort, the temperature gradient will be maintained a constant.

Aside from these advantageous features, the use of a retort having a relatively large transverse dimension will assist in the production of a coke product having a density only slightly less than that of the original coal and which will be formed in lumps having a hard crust-like exterior. The coke, being of high density, will have a minimum number of cells therein.

It will be possible in accordance with my process and apparatus to regulate the size of the lumps and moreover the degree to which they are coked.

A further advantage of the present invention resides in the use of a retort of large transverse dimension, in that a. great mass of material will be accommodated. The coal first reaches a state of plasticity or semi-plasticity and heretofore has tended to cling to a retort shell. With the present invention, the great pressure exerted by the coal itself due to its depth in the retort causes the portion of the mass adjacent the shell to assume a hard crust-like form. At the same time, the oily vapors produced, because of the depth and density of the mass, find an easier path out of the material, between the mass and the shell, and in this manner form a gaseous layer which prevents the objectionable sticking of the plastic material to the shell.

The fixed depth of coal within the shell causes a pressure to be exerted upon the lowermost portions of the mass and hence the compression caused by this weight will result in densifying the mass as well as increasing the specific gravity of the final product.

In carrying out the invention, reference will behad to the accompanying drawings wherein:

Figure 1 is a side elevation.

Figure 2 is a side view in section of the inlet.

Figure 3 is a side view in section of the outlet.

Figure 4 is a view partly in vertical section showing the receiving means for the coke product.

Figure 5 is a vertical sectional view taken through the lower part of the structure shown in Figure 4, the view being taken in a plane at right angles to the plane of Figure 4.

Figure 6 is an enlarged detail view of a portion of the structure shown .in Figure 4.

Figure 7 is an end view.

Figure 3 is a detail horizontal sectional view on the line 8-8 of Figure 'l.

Figure 9 is a detail view, partly in vertical section, of the supporting structure shown in Figure 'l.

Figure 10 is a detail perspective view of one of the supporting elements illustrated in Figures '7 and 9.

Figure 11 is an end elevation, partly in vertical section, of the retort structure.

Figure 12 is a side elevation. of the retort, and Figure 13 is an end elevation, both. views indi cating how the retort is disposed in positon in the furnace.

Figure 14 is a longitudinal vertical sectional view of the retort.

Figure 15 is a detail longitudinal vertical sectional view of the end structure of the retort and furnace.

Figure 16 is an end view in section showing the retort and the associated furnace structure.

Figure 1'7 is a side view of a modification partly in plan and partly in section.

Figure 18 is a side view of one end of such modification in section.

Figure 19 is a side view in section at the opposite end of such modification.

t Figure 20 is a sectional view of the modifica- Figure 21 is a vertical sectional view through the infeed end of the upper retort shown in Figure 1'7.

Figure 22 is a vertical sectional view on the line 22-22 of Figure 1'7.

Figures 23 and 24 are views of the modified form of apparatus, these views being similar to Figures 9 and 10, respectively.

Referring to Figures 1 and 21 of the drawings, the pulverulent mass of coal, preferably bituminous coal, is fed into a fixed hopper 10 which is mounted upon a suitable support, preferably'adiufiable, and disposed at the feed end of the re- The coal deposited in the said hopper is acted upon by a helical conveyor 11 which, as shown, works in the bottom of the hopper.

The conveyor shaft has keyed to it, at one end, a hub 12 which is rotatably mounted in a bushing 13 carried in one wall of the hopper. Rotatably associated with the hub is a gear wheel 14 meshing with a gear 15 actuated by any suitable mechanism.

The conveyor 11 for the greater portion of its length, is disposed in a tubular member 16 having one end supported by the hopper and communicating therewith and its other end opening into the retort.

The retort end of the tubular member carrying the conveyor will preferably terminate just short of entering the body of the retort, as illustrated in Figure 2.

The retort is indicated as a whole at 17 and is formed of metal sections of cylindrical form capable of withstanding a great weight and pressure as well as the necessary temperatures for distillation and carbonization.

The retort is characterized by having a much larger transverse or diametrical dimension in relation to its longitudinal dimension than is common with ordinary kilns or retorts for this and other purposes.

A retort of the same length as its diameter will perform satisfactorily the purposes as set forth in this application, however, conditions will be encountered where greater length than diameter will be desirable, for instance, wet coal and certain conditions that may for economic reasons make it undesirable to dry such coal. A range of from same length as diameter of retort to three times the diameter in length will cover all conditions that may have to be met. For instance, a retort ten feet in diameter and ten feet lon (both dimensions apply to inside diameter and length of the actual carbonizing chamber) would perform satisfactorily, but in order to meet cer-- tain conditions, a retort ten feet in diameter and thirty feet long would provide suflicient range to meet varying conditions.

The retort is closed at the inlet end by a plate or head 18 which is suitably secured by bolting, 8(1 welding, or otherwise to completely seal that end in a gas tight manner. A central opening 19 defined by an axial extension 20 receives the conveyor 11 and the feed tube 16.

Disposed within one end of the extension 20 and adapted to enclose and support the tube 16 is a suitable-packing means comprising split rings, or one piece packing glands 21 and 22. Between these rings is disposed a flexible packing material indicated at 23. The split ring 22, it will be noted, is in the form of a cylinder and has suitable extensions by which it ,is adjustably connected through the medium of the bolts and nuts 24 to the wall of the hopper 10. In this manner the packing is capable of effecting a close sealing relation between the tube 16 and the extension 20. At this point it should be stated, of course, that when the retort is rotating, the extension 20 will rotate about the packing and the tube 18.

The head 18 may be circular as desired, and 10g adjacent its edge there is formed a lateral extension 25 of stepped formation. This extension 25 is of less longitudinal dimension than the extension 20 as shown in Figure 2. The steps are indicated at 26 and 26', 26 being the longer step; There is defined between the extensions 20 and 25, a space which is packed with any suitable heat insulating medium 27, this being desirable in order to retain all of the heat within the retort.

In the construction shown, a space or clearance is defined between the tube 18 and the extension 20 interiorly thereof so that coal being fed through the tube by the conveyor, may be given a preliminary heating through the medium of gases from the retort. It will be possible, then, by increasing or diminishing the cubical area of i such space as well as its longitudinal extent to subject the coal to a greater or less initial heatmg.

The head 18 is provided with an interior flange 28 preferably circular, which closely fits in an air-tight manner the internal flange 29 of the retort. A suitable recess is formed in the face of the plate or closure and within this recess is disposed a layer of heat insulating and fire-proof 5 material 30. Disposed over this'material is a suitable metallic washer 31 having an opening aligning with the opening in the retort and extension 20. This washer also assists in maintaining an air-tight joint between the plate and the retort.

The retort is rotatably supported at its ends upon suitable fixed casters or rollers 32. These rollers are mounted upon brackets which are supported preferably upon the base of the furnace.

A pair of the rollers is disposed under the longer 35 steps 26 of the extensions 25, and adjacent the end thereof, are tires in the form of cylindrical members 33. These tires are provided at their base with oppositely disposed flanges 34, one of which is relatively elongated. It will be seen that 149 the tires are adapted to engage the rollers between the flanges 35 thereon and to be supported by said rollers for rotation. The tires are of greater internal diameter than the diameter of v the extensions 26 and within the space defined thereby are disposed the supporting and connecting means 36 for the tires with respect to the step 26 of the extension 25. This supporting and comnecting means as illustrated in detail in Figure 7 comprises a plurality of the members shown in 15 Figure 10 .which are circularly disposed about the extension 25 and connected at one end thereto as shown at 37. The members 36 are formed from a strip of metal which may have varying degrees of thickness and flexibility and will preferably be cut out or slotted intermediate its area and bent as shown so as to form a flexible cushion. The purpose of these members is to allow for contraction and expansion due to the heating and cooling of the parts.

The upwardly bowed portions of the respective members, it will be noted, will engage the underside of the flanges 34 to flexibly and frictionally support the tires 33 in position, as shown in Figure 7. V

One of the flanges 34 is elongated as described previously and shown at 38, and carries a gear 39 which may be keyed thereto in any suitable manner. The teeth 40 of the gear 39 may be meshed with a second gear and actuated in any desired manner.

At this point it may be stated that the operation of the gears 14 and 39 may be controlled so that the speed of rotation of the retort may be timed in accordance with the speed of the conveyor or vice versa. It is desirable in employing the apparatus and the process of the invention to employ a definite ratio of rotation between the retort and the feeding means, and any suitable gearing may be utilized to effect this purpose.

The opposite end of the retort is provided with a construction identical to that described in connection with the inlet shown in Figure 2 with the exception of certain details connected with the discharge of the flnal product which will now be described.

The head 18 at the discharge end and its associated parts are all similar to those already described in the inlet or feed end of the retort and it will be seen that an axially disposed outfeed or discharge extension 41 is integrally connected with the cap plate 18. This discharge passage communicates with a casing or chamber 42. The chamber 42 may be of various dimensions and its detail construction will be later described. As shown in Figure 3, the discharge 41 extends into the adjacent wall of the chamber 42 and asuitable gas-tight packing is associated with these parts. This packing comprises the split ring 43 and the split ring 44 between which is disposed a flexible packing 45 which surrounds and bears upon the outlet 41. Bearing upon the packing just described is a second split ring 46 having a flange 47 engaging the adjacent vertical wall of the chamber 42. The ring 46 is grooved to receive a preferably split packing ring 48 which bears against one side of the flange 47, as shown. The ring 48 is carried by bolts 49 which are threaded into the wall of the casing 42 and on one side carry springs 50 whereby a tightening up of the nuts 49 carried by the bolts will result in a tight engagement of the packing with the adjacent wall of the casing about the outlet 41. Moreover, bolts 46' are adjustably engaged in an upstanding flange of the ring 43 and at one end engage the adjacent end of the ring 46 so that this member can be caused to tightly engage the wall of the chamber 42.

The casing or chamber 42 at its lower end receives a casting 51 forming a vertical extension of the casing. This casting 51, like the casing 42, is preferably rectangular and has two upstanding guide walls which flt within the lower portion of the casing 42. Intermediate its ends the casting 51 is pro ided with an external flange or flanges 51 upon which bears a flange or flanges 42' formed on the casing whereby the casing is supported upon the lower casting 51. The lower casting 51 is in turn supported as shown in Figure 4 upon a suitable receiving structure 52 for the final product which will be later described.

Journaled in the lower casting 51, at its lower end, is a shaft 53 carrying a gear 54 exteriorly of the casting and said shaft is integral with or otherwise rotatably associated with a gate 55 interiorly of the casting as shown in Figures 3 and 4. The shaft 53 is carried in suitable bearings in the lower end of the casting 51 and a packing is provided as will be readily understood. At th s point it should be stated that the gate 55 is of a dimension to closely flt the walls of the casting 51 and acts as a valve.

-also, as shown in Figure 11, journaled in the lower end of the casting 51 are a plurality of shafts 5'7, disposed upon opposite sides of the shaft 53. Each shaft 57 carries a gear 58 which meshes with the gear 54 and also a sprocket gear 59 receiving a sprocket chain 60.

Referring to Figure 4, it will be observed that the gate 55 will selectively control the passage of material discharged into the chamber 42 into one or the other of a plurality of storage or dis charge chambers 61. The chambers 61 in the receiving structure 52 are separated by a divider plate 62 and the lower end of each chamber 61 is selectively closed by a valve or gate 63. This lattervalve 63 is mounted upon a shaft 64 which is journaled in bearings formed in the depending arms 64', so that the valve may swing to close the bottom of one or the other of the chambers. A sprocket 65 is mounted on the shaft 64 over which passes the chain 60 and keyed to the shaft 64 is a lever 66 to which is connected an operating rod 67.

Movement of the operating rod 67 will move the gate 55 to close the receiving end of one bin and the gate 63 to open the discharge end of the said bin, at the same time opening the receiving end of the other bin and closing its discharge end. This operation of the rod 6'7 may be made automatic at a definite period, or depending upon the weight of material in the respective bin bearing upon the gate 63, or other means.

It will be noted from Figures 3 and 4 that the gate 55 moves flush with the upwardly extending walls of the lower casting and is enlarged as shown at 68 to engage the beveled edges 69 of the other sde walls so as to form a tight closure. The gate 55 is pivotally mounted at the upper end of the divider plate 62 as shown in Figure 6, the divider plate being provided with oppositely disposed plates 70 forming a pocket containing a suitable packing 71 which is engaged by the lower end of the gate as shown in Figure 6. Thus, the bins are sealed from each other at their upper ends by the divider plate 62 and also from the casing 42 when one or the other of the entrance ends of the bins are closed.

The bins are preferably formed of sheet metal and are defined by the divider plate 62 and the inclined outer walls 72, the side walls being, of,

course, vertical. The bottoms of the bins are preferably inclined as shown, and there is provided a double wall construction indicated at 73 with the walls spaced apart. Secured to the opposite sides of the bins is an arcuate trough indicated at 74 which is riveted .to the walls as shown in Figures 4- assesses 4 and 5, and which is provided with flanges at its ends indicated at '75, which flanges fit in the space between the bottom walls 73 as shown. The trough has positioned intermediate its ends a division 76, as shown in Figure 4, which receives and is secured to the lower end of the divider plate 62. In this manner, material passing from either of the bins 61 when the gate 63 is open, will pass through the adjacent opening in the trough on one side or the other of the division member '16.

In this connection, the arms 64' carrying the gate 63 and its shaft 64 are riveted or otherwise secured to the trough at a point substantially intermediate its ends as indicated at 7'7, or may be integral with the trough.

The gate 63 is segmental and its periphery being arcuate is adapted to conform closely to the arcuate contour of the bottom edges of the trough '74 as well as the bottom edges of the flange portion '75 of the trough. In this manner the gate will effectively seal the bottom of either of the chambers 61 as the case may be.

The bins 61 are preferably formed of sheet metal riveted or bolted together to form the enclosed structure and are supported by brackets '78 disposed upon the base of the furnace and, of course, below the level of the furnace bed. as shown best in Figure 1.

The material discharged from either bin 61 by the opening of the gate 63 is deposited upon a suitable endless conveyor '79 and carried to the point of distribution.

The chamber 42 is likewise preferably formed of sheet metal and in its top is provided with an outlet pipe '79 for volatile distillation products which pass from the passage 41 to the chamber 42 as well as for any volatile produpts which are formed while the coke is in either of the bins 61.

An opening for allowing access to the chamber where necessary is provided and closed by a suitable door or plate 81. Referring to Figure 1, the furnace is provided with the usual base upon which is disposed a layer or layers of fire brick' in Figures 2 and 3 has an opening and fits about the peripheral edge of the plate 18 with its adjacent edge spaced therefrom. This plate is adapted to cover the space defined by the retort and the adjacent wall of the furnace and by reason of the space between the edge of the plate 18 and the edge of the plate 83 closing the end of the furnace, clearance is allowed, as shown in Figure 15,

for expansion and contraction which will occur in a construction of this character. metal plate 84 in the form of a ring is attached to the plate 83 and acts to confine or limit any escape of flue gases which might occur in the space between the respective closure plates.

Referring to Figure 16, there is provided in the furnace walls, a number of vent openings indicated at 85 adapted to be closed by a plurality of sliding doors 86 operated by a sliding lever 8'7. The numeral 88 indicates a sight opening and the numeral 89 indicates one of the openings through which an oil or gas burner is extended.

The retort proper is illustrated in Figure 14 and iscomprised of a plurality of cylindrical sections which are bolted or otherwise joined at their ends and for this purpose are provided with in- A suitable wardly directed continuous peripheral flanges or ribs respectively having a tongue and groove 90. whereby a firm and thoroughly strong joint is provided. The side walls of the flanges constituting the edges of the section 1'7 are inclined as at 80 90', toward the ends of the respective sections, so that when adjacent sections are assembled, a single flange having inwardly tapered side walls will be provided at the adjoining edges of the retort sections. In this manner, unobstructed pas- 85 sage of the material in the retort from one end to the other will be efliciently permitted without objectionable obstruction or collection of the material at the joints between the sections. The flanges, when assembled as shown in Figure 15, 90 will be provided with a flat continuous inner wall 91', which is uniformly spaced from the wall of the retort throughout the periphery of the flange. This construction also aids in assuring unobztiiticted passage of the material through the re- '95 These internal ribs have several advantages, viz: they permit the retort to be built up in section as it would be too expensive to make such a retort in a one piece casting. If ribs were on the 1m outer diameter the heat would attack them and they would soon deteriorate to such an extent as would threaten failure of the retort. The internal ribs are protected against too high a tempera.- ture because the coal inside of the retort is al- 195 ways at lower temperature than the retort shell; therefore, the inwardly projecting ribs will conduct the excess temperature to the coal and at the same time are subject to a constant cooling action by coming in contact with the coal which is at a lower temperature. The inside of retort is neutral and therefore cannot attack the metal. This is of great importance as the strength of the joints is of vital importance and the factors mentioned make it possible to maintain these joints 1'15 unimpaired during the life of the retort.

Referring to Figures 12 and 13, after the furnace has been prepared to receive the retort, the retort is arranged upon cradles 91 mounted on wheels or rollers 92 which move upon tracks 93 1'20 carried by I-beams 94 whereby the retort may be moved into the furnace. Thereafter, suitable tie rods 95 are passed about the retort and secured at their ends to the metal beams at the respective ends of the furnace as indicated at 1 5 96. In this manner the retort will be supported and can be so adjusted as to lie properly within the furnace and in horizontal position therein; The cradles and I-beams are then removed from beneath the retort and the rollers 32 are positioned with proper adjustment to receive the tires 33 and support the retort operatively for production. Thereafter the tie rods 95 are removed.

It will thus be seen that material will be deposited in the hopper 10 and discharged through 185 the tube 18 into the retort. The retort will be rotated and the material will be progressively distilled and carbonized, and in the form of coke lumps of spherical shape will be passed through the discharge 41 into the chamber 42 and drop or collect in either of the bins or chambers 61.

Throughout the process, the apparatus provides for the complete exclusion of air and by having a retort of relatively large cross-sectional dimension with centrally disposed inlet and outlet passages of considerably less diameter, it will be seen that a definite level of coal and coke products must be reached in the retort before the coke products will pass out of the discharge 41. This will beunderstood, since the retort is maintained in horizontal position as distinguished from prior efforts where long inclined treating members have been utilized. V

In other words, the coal and coke products will at all times occupy substantially one-half of the cubical area of the retort and the rate of discharge will depend primarily upon the rate of movement of the feed conveyor 11 and the speed of rotation of the retort 1'7.

By having the bins in communication with the chamber 42 and its flue 79, any volatile products, or the products of any exothermic reactions taking place in the bins in which the treated coke is stored preliminarily will be carried off and hence entrained gases will be eliminated from the final product so far as possible. The coke as delivered will be free of anyobjectionable tar odor which is so noticeable with previous methods when the coke is presented to the atmosphere.

Heretofore, it has only been possible to treat coal containing a considerable amount of bitumen and on which the surfaces exhibit a gummy or resinous condition by submitting the coal to an oxidizing treatment. With the present proc-- ess, however, the gummy or resinous surfaces on the coal are a much desired property and contribute toward producing the density and high specific gravity of the lump product as discharged from the retort.

In some cases where the coals are too low in bitumen and volatile content to develop the desired state of plasticity or semi-plasticity, good results are obtained by adding coal tar pitch to the coal. The coal tar pitch is preferably added in liquid form and is supplied to the retort preferably at a point adjacent the feed end of the retort or at that point where the coal under treat" ment has reached'a semi-plastic state.

In some cases, however, the coal tar pitch may be mixed with the coal prior to its admission to the hopper or while it is in the hopper and being conveyed by the screw 11.

In Figure 1, I have illustrated a pipe 97 which extends through the conveyor shaft and is adapted to discharge into the adjacent end of the retort at 98. This pipe, however, may be carried further into the retort, and the liquid sprayed by any suitable means. Where it is desired to mix the coal tar pitch with the coal while in the hopper 10 and tube 16, the conveyor shaft will be suitably perforated to afford this result.

In Figures 17 to 24 inclusive, is illustrated a modification of the invention which, however, is

characterized primarily by the provision of its superposed retorts and a slightly different feeding and discharge means.

The retorts proper and their associated operating mechanism are all similar to that previously described.

Referring to Figure 1'7, the coal is fed into the hopper 100 and discharged into the retort 101 which is preferably maintained at a temperature below 600 F. where it is preliminarily treated and thereafter discharged into the hopper 102 from whence it vertically drops through the enclosed chute 103 into a hopper 104. From the hopper 104 the preliminarily treated coal is passed into the lower retort 105 and discharged into the chamber 106 in the form of suitable coke lumps.

The respective retorts may be individually heated and if desired the upper retort may be heated by means of the lower furnace in which event the openings 107 in the floor of the upper furnace will be uncovered by means of gates 10%;

shown in Figure 20. The gates are in the form of bars and are provided with eye members 108' levers engaging the eyes and extending externally of\the furnace. This will allow all of the heat genfi ated in the lower furnace to be confined therein when the gates are closed. the flue gases then being removed in any .desired manner. If it is desired, said gates may be opened as described to assist or entirely heat the upper retort. 'In Figure 20 is disclosed one means of operating the gear 39, namely a shaft 109 connected with any suitable source of power carrying a pinion gear 110 at its end engaging the gear 39. It will be understood in this construction that both of the retorts are rotated and they may be rotated in timed relation or at different speeds. Also, the feeding means, as in the previous case, may be regulated in accordance with the speed of rotation of the respective retorts, both retorts being in horizontal position.

The discharging means disclosed in this modiflcation comprise a chamber 106 into which the coke from the retort 105 is passed. The coke is permitted to cool in this chamber until exothermic action has substantially stopped whereupon the gear 111 (Fig.22) is operated engaging the rack 112 to which is connected the gate 113 whereby the feed valve will be opened to permit the material to fall into the chamber 114 which is in open communication with the chamber 106 when the gate is open. The chamber 114 is provided at its lower end with a similar gate 115 which is'operated in a similar manner by means of the rack and pinion and by the mechanism 114 will be delivered into a suitable receptacle or conveyor disposed below the furnace base, in the space indicated at 116.

Having described the apparatus and its operation, the process forming a part of the present invention will now be fully set forth.

As will be understood, the invention seeks to produce low volatile smokeless lump coke of substantially spherical shape and of convenient size for use in stoves, furnaces and other purposes. The coke lumps are unique in that they are free burning, long flaming and are made up of small pieces orparticles conglomerated into a hard solid form of rounded contour possessing a high specific gravity and of sufficient strength to permit handling and transportation without producing objectionable dust or fines.

The products are further characterized by possessing a density, and as stated, a. high specific gravity considerably above that of the usual coke products and not substantially less than the weight of the original coal.

Generally stated, the particular coal which is usually bituminous and possessing varying degrees of volatile constituents and chemical compounds will be fed to the hopper 10. The coal may be initially mixed witlra bitumen such as coal tar pitch if it be deficient in gummy constituent, or this material may be subsequently added to the mass when it is in semi-plastic state within the retort as heretofore set forth.

The coal may be preheated before it enters the retort either in a separate means as disclosed in the modified form of the invention, or preheated by its travel through the tube 16 as heretofore described. Preheating of the coal before it enters the retort is sometimes desirable and where high moisture content is present, as would be the case with washed coal, it is usually necessary to preheat in order to secure large throughput.

-Upon reference to the apparatus disclosed in the drawings, it will be seen that preheating in accordance with this process is carried out with the exclusion of air. In some cases preheating will not be necessary, as where the moisture content of the coal is low and in other cases a mere warming will be sufilcient.

The coal is passed intothe retort which is rotated at a sufiicient speed to pass the material toward the discharge end in accordance with the feed from the conveyor and a definite level will be built up which is substantially one-half of the cubical area of the retort. When the level reaches a point above the bottom of the discharge 41, the coke lumps will pass from the retort into the chamber 42..

The temperature factor of the retort, wherein the distillation and carbonization takes place, will preferably be maintained constant throughout the area of the retort, but if desired, zoning may be resorted to and various portions of the longitudinal dimension of the retort shell subjected to varying degrees of temperature. Zoning, however, is neither contemplated or necessary with this invention.

In carrying out this invention, uniform temperature is applied the full length of the retort. This temperature, of course, will vary in accordance with the nature of the fuel and the speed of rotation of the retort and the feeding means. A constant temperature, of course, is desirable to eliminate the complicated control methods at present in use and is possible because a great quantity of'coal is under treatment and the heat conducted through the retort shell is difiused throughout the bulky mass which is constantly in motion, and this obviates the necessity of any localized temperature application such as zoning. This method is possible also because of the relationship of the diameter of the retort to its longitudinal dimension and because a definite level or batch of material under treament is maintained a constant throughout the process. Thus, the present method and construction are advantageous in that the so-called heat zoning method and accompanying complicated apparatus are unnecessary. Furthermore, it is possible to control the density'of the resultant coke lumps. At the same time it is possible to flow the mass through the retort under absolute control in the same manner as a liquid could be regulated, and maintain at all times a fixed ratio of coal and coke to the cubical content of the retort.

In addition to these features and of fundamental importance is the fact that it is possible to control the uniformity of the coke, because if a portion of the coal should for any reason advance toward the discharge end, ahead of the progressive order, it would be diffused in the mass and treatment would be accelerated in the same manner as would happen if the retort contained water. In other words, if the discharge temperature of the water by comparison was to be 212 F., it would be difficult for a quantity of water to pass out or be discharged at a temperature less than 212 F. This is due to the great quantity or bulk of water which would cause such intermixing as would make it 3 1 1,osa,saa

sible to maintain anything'but a uniform discharge temperature. The action which takes place within the great mass of coal is substantiallysimilartothatwhichwouldoccurwere a liquid medium utilized as in the above example.

Because of the construction of the retort, there is always present a large and heavy mass of coal, semi-plastic and plastic material, and coke products in various degrees of formation. Since the retort is constantly rolling, the weight of these would naturally exert a great pressure with the result that the final product is extremely dense and hard.

The coal in its passage through the retort will first reach a semi-plastic stage and as it is carried about by rotation of the retort due to volatilization, parts of the plastic mass will separate and roll down or over the inclined surface provided by the more plastic portion which is closer to the retort shell and is being carried upward. In this manner all portions of the mass will be given a thorough distillation and carbonization treatment in accordance with requirements and there will result, of course, a progressive removal of volatiles and moisture. The mass will be pro gressively fed from the inlet and toward the outlet end of the retort and because there is a considerable weight of material in the retort, the mass will be subjected at all points to a heavy pressure, the ultimate result of which is a coke product of greater density only slightly less than the density of the coal as fed to the retort.

Heretofore, there has been a tendency of the plastic mass to cling to the wall of the retort, which in the present instance is eliminated due to the large cubical area occupied by the coal and the pressure exerted thereby. Thus, when the mass in the shell is in direct proximity to the furnace, resultant volatilization will cause a gas cushion to form between the mass and the adjacent shell wall, since the gases will follow the most available path. In other words, the gases cannot pass up through the heavy mass, as easily as they will exude from the mass adjacent the retort wall. This, of course, is due, as stated, to the great pressure exerted by the large content of coal in the retort.

This gas or vapor cushion is the means of causing eifective separation between retort shell and the semi-plastic mass.- There is an entrapment of the gas between the shell and the mass at all times, so that in its various conditions of plasticity, the mass will always separate or break oil from the shell. In this manner clinging is eliminated.

The heat supplied to the retort will be a constant throughout the retort and, therefore, as the smaller parts separate from the plastic initial mass, as it is moved in the retort, they will be progressively treated to additional volatilization. However, the practical result can best be described by stating that the semi-plastic particles of various sizes as they break oil! from the mass collect upon themselves, by adhesion, smaller and more completely dried portions, so that in effect the final product consists of a semicoke, the exterior of which is hard and crustlike and has embedded within it a large number of smaller particles or pieces which are likewise hard and crust-like, but which adhere to the more plastic interior.

Referring to a specific treatment, the comminuted coal, either in raw state, dried, or preheated as desired, is fed to the retort by means of the conveyor 11. This coal it will be noted, is 

